Polymerization catalyst



United States Patent 01 fice 3,418,304 Patented Dec. 24, 1968 3,418,304 POLYMERIZATION CATALYST Arthur W. Langer, .lr., Watchung, and John W. Harding,

Westfield, N.J., assignors to Esso Research and Engineering Company, a corporation of Delaware N Drawing. Filed Sept. 13, 1963, Ser. No. 308,675 15 Claims. (Cl. 26093.7)

ABSTRACT OF THE DISCLOSURE A polymerization catalyst of improved stereospecificity is formed by combining a reduced transition metal compound (such as TiCl with the reaction product of a Lewis acid (such as AlCl and an alkyl metal compound which is a weak cocatalyst and which contains nitrogen, oxygen, or sulfur. The catalyst composition is particularly suitable for the polymerization of alpha-olefins having 3 or more carbon atoms.

This invention relates to novel stereospecific polymerization catalysts and their use in the polymerization of propylene and higher alpha olefins.

Prior to the present invention, it was found that alpha olefins could be polymerized and copolymerized at low pressures in the presence of various combinations of reducing metals or metal compounds, e.g. alkali and alkaline earth metals, their hydrides and alloys; aluminum hydrides, aluminum alkyls, alkyl aluminum halides, and the like in combination with various heavy metal compounds such as the halides, acetyl acetonates, and the like, of the metals of Group IV through VI and Group VIII of the Periodic System, e.g. of titanium, zirconium, vanadium, chromium, molybdenum and iron. See, e.g. Belgian Patent No. 533,362, Chemical & Engineering News, Apr. 8, 1957, pages 12 through 16 and Petroleum Refiner, December 1956, pages 191 through 196.

It is also known that the use of Lewis bases as third components with certain of the above combinations will increase their activity and stereospecificity in the polymerization of propylene and higher alpha olefins. However, Lewis bases, as is shown in the accompanying data, are of no value at all in the present invention.

In this invention, Lewis acids, such as AlCl are used to form reaction products or complexes with a specific class of alkyl metal compounds. These complexes in combination with transition metal compounds form catalysts which are highly stereospecific for the polymerization of polypropylene or higher alpha olefins.

More specifically, the complex or reaction product is formed by adding the Lewis acid to the alkyl metal compound in an inert hydrocarbon diluent, such as xylene or heptane, or the components may be mixed in the absence of diluent. About 0.5 to 1.5 moles of Lewis acid is mixed with each mole of alkyl metal compound, although preferably one mole of Lewis acid is used per mole of alkyl metal compound. The temperature of reaction is not critical although it is best to react the materials at about 20 C. to +60 C. The resulting reaction product is then mixed with a partially reduced transition metal compound in a mole ratio of 0.1 to 1 to to 1, preferably 0.2 to 1 to 2 to 1. A catalytic amount of this total composition is then contacted with the monomer. It is desirable to add the complex to the transition metal compound prior to the addition of the monomer.

The Lewis acids (electron pair acceptors) of this invention have the formula MX where M is an ion of a metal selected from the group including aluminum, gallium, indium, magnesium and beryllium. These are the most active Group II-A and III-A metals. Further, X is chosen from anions of any of chlorine, bromine, or iodine; and n is equal to the valence of the metal, M. Preferably X is Cl, and M is aluminum. Examples of these Lewis acids include AlCl MgCl MgBr A11 and BeCl Most preferred is AlCl The alkyl metal compounds of this invention are defined by the following formulas: R MNR' R MOR, R MPR and R MSR'.

M in the above formulas represents the ions of the more active Groups II-A and III-A metals, i.e., the ions of aluminum, gallium, indium, magnesium and beryllium. Preferred is aluminum.

)2 in the above formulas is an integer which is equal to the valence of M for the Lewis acid, and the valence of M minus one for the alkyl metal.

R and R in the general formulas above, may be the same or different monovalent hydrocarbon radicals. Examples of suitable R and R groups include aryl radicals; aliphatic hydrocarbon radicals or derivatives, such as alkyl, cycloalkyl-alkyl, cycloalkenyl-alkyl, aryl-alkyl, cycloalkyl, aryl-cycloalkyl, cycloalkyl-alkenyl, alkyl-aryl or cycloalkyl-aryl radicals.

Specific examples for R and R groups for substitution in the above formulas include methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, n-amyl, isoamyl, n-hexyl, n-octyl, n-decyl, and the like; 2-butenyl, 2-methyl-2-butenyl and the like; cyclopentyl-methyl, cyclohexyl-ethyl, cyclopentyl-ethyl, methylcyclopentyl-ethyl, 4-cyclohexenylethyl, and the like; 2-phenylethyl, 2-phenylpropyl, a-naphthylethyl, methylnaphthylethyl, and the like; cyclopentyl, cyclohexyl, 2,2,1-bicycloheptyl, and the like; methylcyclopentyl, dimethylcyclopentyl, ethylcyclopentyl, methylcyclohexyl, dimethylcyclohexyl, ethylcyclohexyl, isopropylcyclohexyl, S-cyclopentadienyl, and the like; phenylcyclopentyl, phenylcyclohexyl, the corresponding naphthyl derivatives of cycloalkyl groups, and the like; phenyl, tolyl, xylyl, ethylphenyl, naphthyl, methylnaphthyl, dimethylnaphthyl, ethylnaphthyl, and cyclohexylphenyl.

Preferably R is a lower alkyl group having 18 carbon atoms such as ethyl and hexyl, and R is a lower alkyl group having 1-4 carbon atoms such as ethyl and propyl. Ethyl is particularly preferred for R and methyl or ethyl for R.

Examples of preferred complexes between the Lewis acid and the alkyl metal compound include Et AlNEt -AlCl Bu AlOMe-A1Cl BuMgNEt -AlCl BuMgNEt MgBr and Et AlSMe-AlBr (In the preceding formulas Et represents an ethyl group, and Bu represents a butyl group.)

The partially reduced transition metal compound of this invention is a partially reduced compound of a metal of Groups IV-B, V-B, VI-B, and VIH. Examples of these metals are titanium, vanadium, chromium, zirconium, tungsten, and molybdenum; titanium is preferred. These may be combined with inorganic groups in the form, for example, of halides, oxides, or hydroxides; or they may be combined with organic groups as for example alcoholates and acetonates. Titanium halides such as TiX and TiX are most stereospecific, and of these the crystalline forms of TiCl and co-crystallized TiCl -AlCi are preferred. The most preferred form is the violet crystalline TiCl known as uTiCl The reduced transition metal compound may be prepared by methods known in the art (see for example, US. Patent No. 3,046,264, issued July 24, 1962).

After the reaction product or complex of the Lewis acid and the alkyl metal compound is formed, this component of the catalyst is mixed with the partially reduced transition metal compound. As a matter of convenience, each component is dispersed in an inert organic diluent which can also serve as the polymerization medium. The catalyst components can also be mixed in situ, i.e. by placing each separate catalyst component in the polymerization reactor which contains an inert organic diluent, allowing the cata- 4 lize catalyst residues. The precipitated product is then filtered and Washed with more alcohol and may then be finished by the addition of suitable stabilizers and inhibitors followed by drying according to methods now well lyst components to be admixed, and injecting the desirable 5 known in the polymer field. monomer. The monomers which are advantageously polymerized Suitable examples of the inert organic diluent, which by this invention are alpha olefins having at least 3 carshould be a liquid at the operating conditions of the polybon atoms. While the invention is preferably applied to merization reaction, include aliphatic hydrocarbons such straight chain monoolefins, and most preferably to polyas pentane, hexane, isooctane, and the like; cycloaliphatic propylene, the invention is also useful in the polymerizahydrocarbons such as cyclopentane, cyclohexane, decahytion of other kinds of alpha olefins. Additionally the indronaphthalene, and the like; aromatic hydrocarbons such vention may be applied to produce copolymers of these as benzene, toluene, ethylbenzene, xylene, tetrahydroolefins where it has particular usefulness in tailoring the naphthalene, and the like; halogenated aromatic hydrocarproduct to meet specific requirements since the catalyst can bons, e.-g. monoor di-chlorobenzenes, and the like. Alchange the monomer reactivity ratios relative to conventhough the concentrations of the catalyst components are tional catalysts. Finally the invention may be advantagenot critical, sufiicientamounts of the diluent are employed ously used to produce block copolymers of the above such that the concentration of each component is normally monomers. in the range of 0.01 to 10 g./l., preferably 0.1 to 5 g./l. Suitable examples of C and higher alpha olefins include In preparing and using catalysts according to this instraight chain monoolefins such as propylene, butene-l, vention, :all steps should preferably be carried out in the hexene-l, octene-l, decene-l, and the like; branched chain absence of oxygen, moisture, carbon dioxide or other monoolefins such as 3-methyl-l-butene, 3-methyl-1-penharmful impurities. This may be readily accomplished by tene, 4-methyl-l-pentene, 6-methyl-1-heptene, and the like; blanketing all the raw materials, i.e. the catalyst comdiolefins such as butadiene, isoprene, hexadiene-LS; and ponents, monomers, inert diluents, etc., with an inert gas the like; styrene, vinyltoluence, and the like, polar monosuch as dry nitrogen or argon. Electron donors such as mers such as acrylonitrile, vinyl chloride, ketones, olefin amines, mercaptans, ketones, aldehydes, etc. are generoxides, and the like. ally poisonous to the catalyst system and it is generally This invention may be more fully understood by referdesirable that the monomer contain less than about 200 ence to the following examples:

p.p.m. and the diluent less than about 50 p.p.m. by weight of these impurities. Preferably all materials are purified, EXAMPLE 1 e.g. by drying, distillation, etc. prior to their use.

The polymerization reaction is carried out at a tempera- The complex W Prepared by mlxmg AICIB ture ranging f about C. to about C, (0.002 mole) with 0.314 g. Et AlNEt (0.002 mole) in ferably C. to C. The monomer is allowed to f1() ml. xylene under a dry nitrogen atmosphere at 25 C. remain in contact for a period of time ranging from about a glove After 15 mmutes, Vlolet alpha 0.1 to about 30 hours, preferably 0.3 to 6 hours, during Ticls (ball milled 6 y (0004 111016) Was added and hi h i more monomer may b added so as to maintain the slurry stirred an additional 5 minutes. The catalyst the total pressure at the desired level which may be as low Slurry was then rinsed into a 300 AmiIlcO bomb with as atmospheric and as high as 5000 p.s.i.g. but preferably 10 Xylene and sealed- Cold, liquid Propylene i i th range f 5 to 500 i was charged to the bomb and the bomb was heated with Th amount f monomer dd d ill, of course, b d rocking to 85 C. for 2 hours. The heat was turned ofi termined by catalyst activity, reaction time, diluent voland the bomb allowed to 0001 Overnight While IOCkiIlgurne, desired monomer conversion, etc., but may advan- Polymer was isolated by a standard procedure consist tageously be in the range of about 10 g. to about 100 g, ing of the following steps: (1) addition of 2 l. isopropyl monomer per g. total catalyst when the reaction is carried alcohol and 5 m1. acetylacetone, (2) blending 10 min. out batch wise. Normally it is desirable for good operin a high Speed laboratory Waring Blendol', filtering, ability to limit the concentration of polymer in the diluent r y g e polymer with 0.5 l. boiling isopropyl to less than 20 weight percent. If necessary, the polymer 91601101, filtering While Washing filtfil' cake concentration may be maintained at or below this level With acetone, (7) wetting the filter cake with acetone conby the addition of more diluent during the polymerization taining 0.8 g./l. inhibitor ('2,6-ditertiary-butyl-p-cresol), reaction. and (8) vacuum drying at 80 C. for 12 hours.

At the end of the reaction, the solid polymer is precipi- The results are shown in the first column (A) of Table tated and deashed with the .aid of about 0.2 to 20 volumes I. The control run in the absence of AlCl is shown in of a C -C alcohol such as methyl alcohol, ethyl alcohol, column B. High molecular weight polymer possessing isopropyl alcohol, n-butyl alcohol, and the like. Addihigh. crystallinity, as shown by tensile strength and density, tionally, chelating agents or acids may be added to solubiwas obtained with the complex activator whereas the con- TABLE I.PROPYLENE POLYMERIZATION [300 ml. Rocking Bomb] Run A B C Catalyst:

(a) Additive A1013 None HMPA (b) man er: tan-fies" amid; .314 0. 314 0. 314 azaar- W Polymerization: ld/4 2/2/4 Xylene, ml 50 50 50 Propylene, g 50 50 Temp, 35 85 Time, hours 2 2 2 Ylold, g 30. s 55. 9 1. 7 iiiiiiiia v18 (11/ lensing...Matwiszib jj:::::::::::::::::: E33 :433 2 2613 Tensile, 2/min. (Yield) 4, Percent Elong., 2"lmin. (Yield) 15 Tensile. 2"/min. (Break) 3, 510 Percent Elong., 2"lmin. (B 630 Density 0. 9022 1 Hexamethylphosphoramide.

trol run gave almost completely atactic polymer. Thus, the AlCl converted the non-stereospecific EtgAlNE g activator into a new structure which is highly stereospecific. This is a surprising result since AlCl is a Lewis acid whereas the prior art additives for increasing stereospecificity of the common alkyl metals, such as R AlCl or R Al, were Lewis bases. Column C shows a control run using one of the most effective Lewis base additives, hexamethylphosphoramide (HMPA), which caused almost complete loss of activity.

EXAMPLE 2 Et Al-guaiacol(o-methoxyphenoxy aluminum diethyl) was prepared by mixing 0.4 molar solutions of guaiacol in xylene with A1Et in xylene and heating for min. at 80 C. The solution was cooled to C. and diluted with xylene to 0.05 molar. The complex with AlCl was prepared in the same manner as described in Example 1 but using 0.42 g. Et Al-guaiacol (0.002 mole). The remainder of the catalyst preparation, polymerization and polymer isolation was carried out as in Example 1.

The results are summarized in Table II, column D and a control run in the absence of AlCl is shown in column E. Despite the fact that the control was run a longer time at lower temperature and utilized higher aluminum alkyl concentrations (both conditions favor higher stereospecificity), the complexed catalyst gave significantly higher polymer crystallinity as shown by the higher density and tensile strength.

EXAMPLE 3 The procedure of Example 1 was repeated except that the alkyl metal compound was Et AlOEt. The results are shown in Table II (column F) together with a control run in the absence of AlCl (column G). Again a remarkable increase in stereospecificity was obtained using the AlCl -complexed catalyst. This result is clearly not due to transalkylation between Et AIOEt and AlCl because this would yield EtAlCl which is known to produce only atactic polymer. Although complete alkyl exchange to form Et AlCl is highly improbable, even this would fail to give the high stereospecificity achieved by the complex of this invention as shown by the Et AlCl control run in column H.

BuMgNEt -MgBr -l-alpha Tic1 Improved polymer properties are obtained as a result of higher stereoregularity.

The advantages of this invention will be apparent to 15 the skilled in the art. Novel catalyst systems of high activity and stereospecificity are made available for polymerizing and copolymerizing a wide range of alpha olefins. The polymers thus produced have superior characteristics as regards molecular weight, crystallinity, and

2 mechanical properties.

It is to be understood that this invention is not limited to the specific examples which have been offered merely as illustrations and that modifications may be made without departing from the spirit of the invention.

25 What is claimed is:

1. A catalyst composition comprising a partially reduced transition metal compound in combination with the reaction product of (a) a Lewis acid of the formula MX and (b) an alkyl metal compound having a formula selected from the class consisting of R MNR' R MOR and R MSR, the mole ratio of Lewis acid to alkyl metal being in the range of about 0.5 to 1.5, where (1) R and R are monovalent hydrocarbon radicals,

(2) M is selected from the class of Al, Ga, In,

Mg and Be,

(3) X is selected from the class of Cl, Br and I,

40 (4) n equals the valence of M for the Lewis acid and the valence of M minus one for the alkyl metal. 2. The composition of claim 1 wherein R is a C to C alkyl group, and R is a C to C alkyl group.

3. The composition of claim 2 wherein M is aluminum.

TABLE II.-PROPYLENE PO LYME RIZATION [300 m1. Rocking Bomb] Run D E F G H Catalyst:

(a) Additive None AlCla None None .t 0.052 (b) Alkyl Metal EtgAl-qnaiaeol 1 EtaAlOEt EilgAlOEt Et2AlCl 0. 42 0. 42 0. 052 0. 26 0. 048 (c) a TiClngn 0. 62 0. 62 0. 62 0. 62 0. 62 Mmoles a/b/c 2/2/4 0/2/4 0. 4/0. 4/4 0/2/4 0/0. 4/4 Polymerization:

50 50 50 50 50 50 50 50 85 85 85 85 S5 2 2 1 2 2 2 50 24 20 54 35 Properties:

Inherent Vis., dlJg 5. 20 2 16.0 5. 21 2. 35 4 2 Kinsinger M01. Wt.X10' 690 2,850 690 255 550 Tensile, 2/min. (Yiel 4, 120 3, 360 3, 610 716 2, 530 Percent Elong., 2"lmin. (Yield 18 21 233 31 Density 0. 8993 0. 8925 0. 8995 0. 8762 0. 8933 1 The quaiacol radical=ortho-methoxyphenoxy.

2 Polymerization was carried out for 1 hour at 25 C. before heating to 85 C. and was responsible for the high molecular weight.

EXAMPLE 4 When the procedure of Example 1 is followed except that 0.628 g. purple VCl (0.004 mole) is used in place of TiCl the polypropylene is more crystalline than that obtained in the absence of AlCl EXAMPLE 5 The procedure of Example 1 is repeated for the polymreduced transition metal compound is a-TiCl 7. A catalyst composition comprising a-TiCl in combination with (ethyl) AlN(ethyl) -AlCl 8. A process for polymerizing alpha olefins having three or more carbon atoms which comprises contacting the erization of butene-l using Et AlNMe -AlCl and brown alpha olefin with the catalyst of claim 1.

9. A process for polymerizing alpha olefins having three or more carbon atoms which comprises contacting the alpha olefin with the catalyst of claim 2.

10. A process for polymerizing alpha olefins having three or more carbon atoms which comprises contacting the alpha olefin with the catalyst of claim 3.

11. A process for polymerizing alpha olefins having three or more carbon atoms which comprises contacting the alpha olefin with the catalyst of claim 4.

12. A process for polymerizing alpha olefins having three or more carbon atoms which comprises contacting the alpha olefin with the catalyst of claim 6.

13. A process for polymerizing alpha olefins having three or more carbon atoms which comprises contacting the alpha olefins with the catalyst of claim 7.

14. The process of claim 13 wherein the alpha olefin is propylene.

15. The composition of claim 3 wherein the reduced transition metal compound is crystalline TiCl or cocrystallized TiCl -AlCl and the alkyl metal is defined by the formula R MNR' References Cited UNITED STATES PATENTS FOREIGN PATENTS 785,314 11/1957 Great Britain.

JOSEPH L. SCHOFER, Primary Examiner.

M. B. KURTZMAN, Assistant Examiner.

U.S. c1. X.R. 

